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Understand the mathematical equation for flow through anoverlapped four-way spool valve.
Understand the mathematical equation for flow through an underlappedfour-way spool valve.
Understand the mathematical equation for flow through athree-way critical center valve.
Understand the mathematical equation for flow through athree-way open center valve.
Describe the working and construction of a flapper nozzle valve and performits mathematical
analysis.
Analyze poppet, single-stage relief and pressure-compensated valves.
Carry out mathematical analysis of valves used inhydraulic systems.
1.1 Introduction
Most hydraulic servo mechanisms or other high-performance systems rely for their operation on the
metering of fluid through a valve. This chapter deals with a linearized method of analysis for fourway valves. They are called so because they have four connections, one for the supply pressure and
another for the exhaust, and two control ports through both of which fluid may be metered, from the
supply to either the system or the exhaust.
Metering valves are never fully open and their use is for accurately metering the flow of fluid through
them. In this case of spool valves, longitudinal displacements of the spool are always small as
compared with the spools diameter.
1.2 Four-Way Spool Valves
A spool valve used for metering purposes controls flow rate by throttling.Each port in a valve that is
partially closed by a land on the spool becomes a control throttle.
The rate of flow of fluid through such a valve depends on the spool displacement from the null
position x and on the pressure upstream and downstream of the valve. One way of representing the
flow rate q through a valve is
q Kq x Kc pm
(1.1)
whereqis the volume flow rate of the oil, Kq is the flow gain, Kc is the pressureflow coefficient and
pmis the pressure difference across the load.Equation(1.1) implies that the flow rate is directly
proportional to the valve opening and directly proportional to the pressure drop.
1.2.1 Critical Center Valve
In critical center valves, the lands of the spool are exactly of the same width as the annual ports of the
valve body in the central or null position where the lands exactly cover the ports (Fig. 1.1).
Load
Orifices are a basic means for the control of fluid power. Flow characteristics of orifices play a major
role in the design of many hydraulic control devices. An orifice is a sudden restriction of short length
in a flow passage and may have a fixed or variable area. Two types of flow regime exist depending on
whether inertial or viscous forces dominate. The flow through orifice must increase above that in the
upstream region to satisfy the law of continuity. At high Reynolds number, the pressure drop across
the orifice is caused by the acceleration of the fluid particles from the upstream velocity to the higher
jet velocity. At low Reynolds numbers, the pressure drop is caused by the internal shear forces
resulting from fluid viscosity.
The pressure difference required to accelerate the fluid particles from the lower upstream velocity to
higher upstream velocity is found by applying Bernoullis equation and continuity equation. Here we
will not derive the basic equations. Students are advised to go through any standard fluid mechanics
books for the derivation of flow through orifice.
From fluid mechanics, flow through the orifice is given by
q1 Cd d1 x( ps p1 )1/2 (2 / )1/2
(1.2)
q2 Cd d1 x( p2 pe ) (2 / ) (1.3)
1/2
1/2
q1 q2
2.
( ps p1 ) ( p2 pe )
pe is negligible
ps pm 2 p2
(1.4)
ps pm 2 p1
(1.5)
(1.6)
With the type of configuration illustrated in Fig. 1.1, it is usually accepted that
(1.7)
Cd 5/8
= 870 kg/ m3
(1.8)
Using values given in Eqs. (1.7) and (1.8) in Eq. (1.6) we get
q 6.7d1 x( ps pm )1/2
(1.9)
The assumption that the valve opening can be treated as orifices pre-supposes that x is small
d1 so that the pressure drop across each orifice will be significant compared with ps . In
p
p
practice the pressure difference across the load m rarely exceeds 0.666 s . Allowing further
p 0.666 ps , then less than 10% error is involved using the binomial
simplification of Eq. (1.9) if m
compared to
ps pm
1 p
ps 1 m
2 ps
(1.10)
Kq 6.7d1 ps1/2
Kc 6.7d1 xp
1/2
s
/ 2 ps
(1.11)
(1.12)
(1.13)
The above analysis predicts that the flow gain K q can be treated as constant for a particular valve and
supply pressure but the pressure flow coefficient K c varies with the valve opening x. The variation of
In reality, spool lands never exactly match the annular ports in the valve body. Actual test results with
a constant pressure drop across the valve ports show variations, particularly near the central or null
position of the spool as those illustrated in Fig. 1.2.
The flow gain K q is the slope of the approximate line in the figure, which can double its valve near
null with negative lap. The magnitude of K q is the most important parameter of a valve and often also
of any system incorporating the valve.
Zero lap
Overlap
Underlap
Figure 1.2Flow rates versus valve displacement for constant pressure drop.
(ux)
(u+x)
(ux)
(u+x)
Load motion
Load
Referring to Fig. 1.3,a displacement of x(say to the left) unbalances the symmetry of the ports. Two of
the annular orifices increase in width from u to u + x and two decrease from u to ux.The flow
ratesare estimated as follows:
1/2
2
q1 Cd d1 (u x)( ps p1 )
1/2
1/2
2
Cd d1 (u x)( p1 pe ) (1.14)
1/2
1/2
2
q2 Cd d1 (u x)( p2 pe )
Let us make following assumptions:
1/2
1.
q1 q2
2.
ps p1 p2
1/2
2
Cd d1 (u x)( ps p2 )
1/2
(1.15)
pe is negligible
Writing pm p1 p2 , we can use these assumptions in Eqs. (1.14) and (1.15) and get
1/2
1
q Cd d1{(u x)( ps pm )1/2 (u x)( ps pm )1/2 }
that may be approximated as
1/2
1/2
1/2
1 pm
1 pm
1
1/2
1/ 2
q1 Cd d1 (u x)( ps ) 1
(u x)( ps ) 1
2
p
2 ps
1/ 2
1
q Cd d1
1/2
1/2
s
1
2 x Cd d1u
ps1/2 pm
ps
(1.16)
(1.17)
(1.18)
(1.19)
Kc 6.7d1 xps1/2 / ps
(1.20)
The values refer to operation within the underlap region. Outside this region, these valves act as
K
critical center valves with only two active ports. Note particularly that the flow gain q is double that
for a comparable critical center valve (Fig. 152) in the underlap region. Note also significant leakage
flow when the valve is centered (leakage flow at null when the load flow q is zero)becomes
13.4d1 ps1/2 .
Positive valve
displacement
x
x
Positive load
displacement
2
qc = Cd d1x ( ps pc ) forxpositive
1/ 2
(1.21)
1/ 2
2
qc = Cd d1x ( pc pe ) for x negative
Substituting pm = pc ps/2 we get
1/ 2
(1.22)
1/ 2
p
2
qc = Cd d1x s pm for x positive
2
1/ 2
1/ 2
p
2
qc = Cd d1x s pm for x negative
2
thatmay be approximated.Noting that
1/ 2
1/ 2
ps
2 pm
p 2 p
= s 1 m
ps
2
(1.23)
1/ 2
1/ 2
ps
(1.24)
1 2 pm
1
2 ps
(1.25)
we get
1/ 2
1
qc = Cd d1x ( ps )1/ 2
Cd d1x ( ps )1/2
1
pm
ps
(1.25)
where the positive sign is associated with negative values of x and negative sign with positive
ones.Using Cd (1/ )1/2 6.7 for SI units with pressure in bars we get
Kq= 6.7 d1 ( ps )1/ 2
(1.26)
Kc= 6.7 d1 x
pm (1.27)
ps
(ux)
(u+x)
2
q1 = Cd d1(u + x) ( ps pc )
1/ 2
(1.28)
1/2
1/2
1
pm
1
ps
(1.29)
2
q2 = Cd d1(u x) ( pc )
1/ 2
(1.30)
q2 Cd d1(u x) ps
1/2
1/2
1
pm
1
ps
(1.31)
1/ 2
Cd d1 ps 1/ 2 1 2x Cd d1 ps 1/ 2 1
2u
pm (1.32)
ps
ps
1/ 2
ps
(1.34)
Orifice area
diameter
Load
Flapper
Consider a flopper nozzle valve indicated in Fig. 1.6. We assume that the valve has a balanced
condition such that x = 0 and pm = 0, q = 0. This occurs with the pressure downstream of each of the
fixed orifices iequal tops/2 and when the flow through each orifice equals that through each nozzle,
that is
q1 (steady state) = q3 (steady state) = Cd0 A0 ( ps ps / 2)1/2 (2 / )1/2 (1.35)
(1.36)
and
q1 q2 q3 q4
This also implies that the orifice size and the curtain area in the null position are approximately equal
Cd0 A0 = Cdn d n x0
(1.37)
Consideringthat the valve is not in balance, that is,x has the same value as pm has, we have
q = q1 q2
1/ 2
p
p
K n ps s m
2
2
x x ps pm
Kn 0
2
x0 2
1/ 2
(1.38)
where
Kn Cd0 A0 (2 / )1/ 2 = Cdn dn x0 (2 / )
1/ 2
Also
q = q3 q4
1/ 2
p
p
K n ps s m
2
2
x x ps pm
(1.39)
Kn 0
2
x0 2
1/ 2
p
p
q K n s 1 m
2
2
ps
1/2
1/2
pm
ps
K n 1
2
2
ps
1/2
1/2
ps x ps pm
Kn
2
2 x0 2
(1.40)
1/2
(1.41)
(1.42)
2p
(1.43)
2p
q= Cdx d sin
(1.44)
The momentum of the jet has an axial component equal to v cos (where is the mass flow rate)
that may be written as
Axial component of momentum of jet (
= Mass flow rate Velocity
9
2p
2p
(maxial ) Cd x d sin
cos
(1.45)
where
= Cd d sin2
(1.46)
The axial component of jet momentum is p x.
1.5.2 Single-Stage Relief Valve
Spring loaded valve is illustrated in Fig. 1.8. Let the pressure applied to valve to open is pIt is the
effects of small changes in this pressure from po to po p that are to be considered. The outlet
(exhaust) pressure is assumed to be zero throughout.
(m)
d 2
po
= F+ ksx0+ po x0
4
(1.47)
If the approach velocity is negligible then , given in Eq. (1.46), and the fluid frictional drag force
across the poppet face is neglected.
For some other steady-state position of the poppet (displacement xo x ), another pressure po p
would occur according to
d 2
( po p )
(1.48)
F+ks( xo x ) + ( po p )( xo x )
4
Note that Eqs. (1.47) and (1.48) refer to steady state with poppet stationary. Under dynamic
conditions with the poppet moving, the balance of forces has to take into account the effective mass of
the poppet m and any damping (assumed viscous of rate f) as well as spring, pressure and momentum
forces. For a pressure po p and a poppet displacement xo x , the balance forces become
( po p )
d 2
F+ ksx0 + po x0 + x0 p + (ks + p0) x + f Dx + mD2x
4
(1.49)
10
Assume that the terms involving px are negligibly small. Subtracting Eq. (1.47) from Eq. (1.49), we
get
d 2
p x0= (ks+ po ) x +f Dx + mD2x
p
4
Indicating a second-order relation between changes in pressure p and changes in poppet
displacement x given by
x
K
(1.50)
p 1 2 2
2 D D 1
n
n
where
(d 2 / 4 ) x0
K
(ks po )
= (ks+ po ) /m
This relation suggests that any oscillation of the poppet is associated with much stiffer spring than the
physical spring constant would suggest. As a numerical example, consider a valve of diameter d =
6mm for use at a nominal pressure of po = 70 bar. The projected area equals 28 mm2 , so that the
value of F is approximately 20 N andif this is obtained by initially compressing the spring 10mm, the
spring rate would have a valve of ks = 20 N/mm. Assume that the poppet has a 90 cone angle and
flow coefficient cd = 0.7, then for the valve is about 13.2 mm and po = 92.4 N/mm. The
effective spring rate is not 20 but 112.4 N/mm. If the effective mass were 0.001 kg, then the natural
frequency n of poppet oscillations would be 533 Hz.
1.6 Pressure-Compensated Flow-Control Valve
Figure 1.9 illustrates a pressure-compensated flow-control valve which is designed to pass a constant
flow rate of fluid despite fluctuations of the inlet and outlet pressures. The device has two orifices in
series:one is preset manually to select the desired flow rate, while the other varies with the pressure
difference across the valve. The aim is to keep the flow rate constant by maintaining a constant
pressure difference across the present orifice.
For analysis, changes in the outlet pressure pL represent the disturbances externally imposed on the
device with the inlet (supply) pressure ps assumed constant. This simulates a meter-in control with
the poppet valve partly open and this analysis concerns small changes in this valve opening. The fully
open or fully closed conditions are not dealt with. The datum for spring force acting on the spool is
taken from some arbitrary position of the spool represented by the poppet (i.e., control orifice)
opening of xo .
11
Annular
control orifice
Oil inlet
Moving spool
Spring
Manually
preset orifice
Oil outlet
(1.51)
Under dynamic conditions with the spool in motion for the outlet pressure pLo + pL , with the
instantaneous spool position distance x to the left of its initial position, noting that pCo + pc is the
instantaneous chamber pressure, the balance of forces is given by
{( pCo + pc ) ( pLo + pL } Ap = F ks x { ps ( pCo + pc )}(x+ xo )f Dx mD2x (1.52)
Assuming that pc pL and xare small and the terms pc x may be neglected, subtracting Eq. (1.52) from
Eq. (1.51) gives
pc =
ks ( ps pCo )
f
m
Ap
x+
Dx +
D2x
pL
Ap
x
Ap
x
Ap
xo
Ap xo
o
o
(1.53)
2( p pCo )
q0 = Cdx0 d s
1/ 2
(1.54)
Under dynamic conditions, the flow rate through the control orifice will no longer be equal the flow
through the control orifice is qo qi and that through preset orifice qo qe . The difference between the
two flow rates (into and out from the valve chamber) causes compression of the oil in the valve
chamber or
V
qo qi D pc
(1.55)
12
whereV is the volume of oil and is the effective bulk modules. In Eq. (1.55),V is assumed to be
constant.The flow rate through the control orifice may be written as
1/2
2
qo qi Cd ( x xo ) d { ps ( pCo pc )}2 Ap Dx
Subtracting Eq.(1.54)from Eq. (1.56) neglecting the terms involving pc x we get
qi =
q
qo
pc
+ o x +ApDx
2 ps pCo
xo
(1.56)
(1.57)
and similarly for the change in flow rate through the preset orifice,
qe = =
qo
pc
q
pL
o
2 ps pLo 2 pCo pLo
(1.58)
qi qe = Ap Dx+
qo
q
q
pL
1
1
x+ o
o
pc
2 pCo pLo 2 ps pCo pCo pLo
xo
(1.59)
Also equating Eqs. (1.55) and (1.59) after substituting Eq. (1.53) for pc and after differentiating, for
D pc to obtain pc andD pc terms of pL and x leads to (closed loop) relation between displacements of
the spool and changes of the outlet pressure
ao D3 x + a1 D 2 x + a2 D x + a3 x = K pL + TD pL (1.60)
x
K TD
(1.61)
pL ao D3 a1 D 2 a2 D a3
where
a3 ks Q
qo
( Ap xo )
xo
V
a2 fQ ks Ap ( Ap xo )
V
a1 mQ f
V
a0 m
V
T Ap
qo
qo
xo
2 ps pCo
2 pCo pLo
qo
qo
Q=
ks ks ( Ps PCo )
This linear equation is obviously difficult to apply particularly as the coefficients depend on the initial
conditions that might be classed as the normal operating conditions. In practice,the valves of this
type can be unsatisfactory at initial stage. The relation does indicate that a value is stable if a1a2 is
greater than a3 ao and confirms that increasing the viscous damping helps to stabilize the valve,
increasing both a1 and a2 .
13
Example 1.1
A four-way valve with full periphery annular ports has a 6 mm diameter spool and it may be assumed
that the spool lands fully cover the valve ports in zero or mid-position. Estimate the flow rate through
one port when the pressure drop across it is 70 bar for every mm of spool displacement.
Solution
Spool diameter (d) = 6mm
Pressure drop (p) = 70 bar
Spool displacement (x) = 1mm
By the orifice flow equation, theflow rate is
q Cd dx 2p /
Letting Cd = 5/8 and = 870 kg/m3 and pin bar, we have
q 6.7dx 2p
Therefore,
q= 6.7 (6 103) (1 103)
q= 1.494 103 m3/s
2 70
Example1.2
What would be the flow coefficient Kq of the above valve if it is used as part of a servo system
having oil supply pressure: (a) 140 bar, (b) 210 bar?
Solution:
(a) Supply pressure (ps) = 140 bar. We know Kq 6.7d ps . Therefore,
Kq = 6.7(6 103) 140 = 1.494 m3/s/mm
(b)Supply pressure (ps) = 210 bar. We know Kq 6.7d ps . Therefore,
Kq = 6.7 (6 103)
Example1.3
A three-way spool valve with half the annular periphery of the valve port blocked off and spool
diameter 9 mm is used in a system supplied with oil at 120 bar pressure. The half-area piston has
areas 0.004 m2 and 0.002 m2 and a maximum required velocity 0.3 m/s. Estimate the maximum spool
displacement required. (Assume one-third pressure drop through valve.)
Solution: Supply pressure (ps) = 120 bar. Spool diameter (d) = 9mm. Piston area (Ap) = 0.004m2.
Maximum velocity (v) = 0.3m/s. Maximum valve flow rate is
Q = Ap v = 0.0040.3 = 1.2 103 m3/s
Pressure difference across load (pm) = 40 bar (one-third of supply pressure).
For a three-way valve with half-area piston, the pressure drop is
p = (ps/2) pm = 20 bar
Also from the orifice equation we can write
14
q= 6.7 (9 103) x
2 20
q= 1.198 x
Equating two values of Q and q, we have
1.2 103 = 1.198 x
x = 1.0016mm.
As half the annular periphery of valve is blocked, for the same flow rate, the displacement required is
twice the calculated value.Therefore, the valve displacement is
y = 2 x = 2.003mm
Example 1.4
In a 240-bar servo system employing a four-way valve, a valve underlap is used to assist in damping
system oscillations. The valve has a 4-mm-diameter spool, full periphery ports and nominal underlap
of 0.0127 mm. Estimate the pressureflow coefficient Kc for the valve.
Solution: Supply pressure (ps) = 240 bar. Spool diameter (d) = 4mm. Underlap(u) = 0.0127mm. We
know
Kc
15
Objective-Type Questions
Fill in the Blanks
1. In critical center valves, the lands of the spool are of the ______ as the annual ports of the valve
body in the central or null position where the lands exactly cover the ports.
2. A valve in which the land of the spool never completely covers the ports of the valve body is said
to be ______.
3. ______ is commonly used as the first stage of two-stage servo valves.
4. A pressure-compensated flow control valve is designed to pass a ______ of fluid despite
fluctuations of the inlet and outlet pressures.
5. Flow gain can be treated as ______ for a particular valve and supply pressure.
State True or False
1. The central spool position just closes both the supply and the exhaust port of the valve.
2. Most hydraulic servo mechanisms or other high-performance systems rely for their operation on the
metering of fluid through a valve.
3. Metering valves are always fully open and their use is for accurately metering the flow of fluid
through them.
4. A spool valve used for metering purposes controls flow rate by throttling.
5. A pressure flow coefficient will vary with valve opening and the variation of pressure flow
coefficient are of major significance for linear analysis.
Review Questions
1. Discuss in detail the flowdisplacement relationship of a critical center spool valve, giving its
possible applications in hydraulic control valves.
2. Discuss in detail the flow forces acting on apressure-compensated flow control valve and derive an
expression for these forces.
3. Derive an expression for the flowdisplacement relations of anunderlapped four-way valve.
4. Derive an expression for the flow for a flapper nozzle valve.
5.What is the major limitation of a flapper nozzle amplifier and how it can be overcome?
6.Why is a feedback system used in a multistage servo valve?
7. What is a critical center valve?
8. What does an underlapped four-way valve mean?
9. Give two applications of a flapper nozzle valve.
10. How is a higher flow rate achieved in an electrohydraulic servo valve?
11. Why is a feedback system used in a multistage servo valve?
12. Illustrate the two different types of feedbacks used in a multistage electrohydraulic valve?
13. What is the major limitation of a flapper nozzle amplifier and how it can be overcome?
Answers
Fill in the Blanks
1.Same width
2.Underlapped
3.Flapper nozzle valve
4.Constant flow rate
5.Constant
State True or False
1.True
2.True
3.False
4.True
5.False
16
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